Resol Binder with Amorphous Silica for Casting Molds

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Solution Overview

Problem

CO2-curable resol binders used in metal casting lack the mechanical strength of PU cold box binders, limiting their application to simple cores and not fully addressing emission issues during casting.

Innovation Solution

Incorporating amorphous silicon dioxide into a mold material mixture with a refractory basic material and CO2-curable resol binder to enhance strength and storage life, and improve performance under heat treatment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If CO2-curable resol binders are used in mold material mixtures, then emissions during casting are reduced and working atmosphere is improved, but the mechanical strength of the molds and cores is insufficient

Engineering Contradiction:

Improveemissions during castingVSAvoidmechanical strength of molds and cores

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent combines CO2-curable resol binder with amorphous silicon dioxide to create a composite binder system. This composite material achieves both low emissions during casting and sufficient mechanical strength, resolving the contradiction between environmental benefits and structural performance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical composition parameters of the binder system by incorporating amorphous silicon dioxide into the resol binder. This parameter change enables the binder to achieve both low emissions and high mechanical strength through altered chemical properties and reaction mechanisms.

Inventive Principle:

Principle #35Parameter changes

2Strength

If amorphous silicon dioxide is added to enhance mechanical strength, then the strength level increases significantly, but the complexity of the binder system increases

Engineering Contradiction:

Improvemechanical strength of mold materialVSAvoidcomplexity of binder system

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent optimizes the amount of amorphous silicon dioxide to specific ranges (0.1-5% by weight of binder) to achieve the desired strength enhancement while minimizing system complexity. This parameter optimization ensures that the benefits of added strength are achieved without excessive complication.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The addition of amorphous silicon dioxide significantly increases the mechanical strength of the mold material, both immediately after molding and after storage, and improves the binder's performance under heat treatment, allowing for more complex geometries and reduced emissions.

Implementation Method 1

Incorporating amorphous silicon dioxide into a mold material mixture with a refractory basic material and CO2-curable resol binder to enhance strength

Methodology Applied

Scientific EffectReinforcement:

Implementation Method 2

the addition of amorphous silicon dioxide significantly increases the mechanical strength of the mold material, both immediately after molding and after storage

Methodology Applied

Scientific EffectBonding:

Implementation Method 3

the curing is accomplished in that a gas is passed through the mold material mixture being cured, triggering a chemical reaction

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS9889498B2Mould material mixture containing resols and amorphous silicon dioxide, moulds and cores produced therefrom and method for the production thereof

Publication Date: 2018.02.13 ASK CHEM GMBH

AI summary

The invention relates to mold material mixtures for producing molds and cores for metal casting, consisting of at least one refractory material, a binder based on resols and amorphous silicon dioxide. The invention also relates to a multicomponent system and methods for producing molds and cores using the mold material mixtures as well as molds and cores for metal casting produced according to this method.